Multi-Roll Calender for Processing Active Material Onto a Coating Carrier and Method Thereof

Abstract

The present disclosure provides a multi-roll calender configured to processing material onto a coating. In particular, the present disclosure provides a multi-roll calender and method with a first roll and a second roll configured to form a first nip, wherein the first roll and the second roll laminate a first film on a first side of a foil in the first nip. The system and method may comprise a third roll and a fourth roll configured to form a second nip between the third roll and the fourth roll, wherein the third roll and the fourth roll laminate a second film on a second side of the foil in the second nip.

What is claimed: 
     
         1 . A multi-roll calender, comprising:
 a first roll;   a second roll configured to form a first nip in combination with the first roll, wherein the first roll and the second roll laminate a first film on a first side of a foil in the first nip;   a third roll; and   a fourth roll configured to form a second nip in combination with the third roll, wherein the third roll and the fourth roll laminate a second film on a second side of the foil in the second nip.   
     
     
         2 . The multi-roll calender of  claim 1 , wherein the third roll in combination with the second roll is configured to form a gap. 
     
     
         3 . The multi-roll calender of  claim 2 , where the gap is between 0 and 30 cm. 
     
     
         4 . The multi-roll calender of  claim 1 , further comprising:
 a fifth roll next to the first roll; and   a sixth roll configured to form a third nip in combination with the fifth roll, wherein the fifth roll and sixth roll are configured to receive powder and form the first film from the powder.   
     
     
         5 . The multi-roll calender of  claim 1 , further comprising:
 a seventh roll next to the fourth roll; and   an eighth roll configured to form a fourth nip in combination with the seventh roll, wherein the seventh roll and the eighth roll are configured to receive powder and form the second film from the powder.   
     
     
         6 . The multi-roll calender of  claim 1 , further comprising:
 an idle roll configured to allow the film to contact more surface of the second roll.   
     
     
         7 . The multi-roll calender of  claim 6 , wherein the idle roll is smaller in diameter than the second roll. 
     
     
         8 . The multi-roll calender of  claim 6 , wherein the idle roll is heated. 
     
     
         9 . The multi-roll calender of  claim 1 , wherein the first roll, the second roll, the third roll, and the fourth roll have the same diameter. 
     
     
         10 . The multi-roll calender of  claim 1 , wherein all the rolls are horizontally collinear. 
     
     
         11 . The multi-roll calender of  claim 5 , wherein all the rolls are horizontally collinear. 
     
     
         12 . The multi-roll calender of  claim 1 , wherein all the rolls are supported on a common frame structure. 
     
     
         13 . The multi-roll calender of  claim 6 , wherein the first roll is heated. 
     
     
         14 . The multi-roll calender of  claim 13 , wherein the idle roll puts more of the circumference of the heated first roll in contact with the foil. 
     
     
         15 . The multi-roll calender of  claim 1 , wherein the first film and the second film are the same material or different material. 
     
     
         16 . The multi-roll calender of  claim 1 , wherein the first roll and the second roll at the first nip can apply the same pressure or different pressure as the third roll and the fourth roll at the second nip. 
     
     
         17 . The multi-roll calender of  claim 1 , wherein the dwell time for lamination by the first roll and the second roll at the first nip is the same or different than the dwell time for lamination by the third roll and the fourth roll at the second nip. 
     
     
         18 . The multi-roll calender of  claim 1 , wherein each roll can be heated and the temperature of each roll can be independently controlled. 
     
     
         19 . A method for laminating film onto both sides of a foil, comprising:
 receiving a first film and a foil in a first nip, wherein the first nip is formed by a first roll and a second roll;   laminating the first film on a first side of the foil, using the first roll and the second roll, in the first nip;   receiving a second film and the foil in a second nip formed by the third roll and a fourth roll; and   laminating the second film on a second side of the foil, using the third roll and the fourth roll, in the second nip.